Applications of Additive Manufacturing in Military Simulators Design
Robert GhobrialLM Technical Fellow, Manufacturing Technology Group Leader Seminar ChairLockheed Martin
additivemanufacturingseries.com
SME ADDITIVE MANUFACTURING APPLICATIONS
OCTOBER 23, 2019
GREENVILLE, SC
ROBERT GHOBRIAL
TECHNOLOGY FELLOW – LOCKHEED MARTIN
APPLICATIONS OF ADDITIVE MANUFACTURING IN MILITARY SIMULATORS & TRAINERS
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AGENDA
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1. In the Beginning…
2. Overview of Lockheed Martin
3. The 5Ps AM ModelTM
4. Applications in Military Simulators
5. AM Technology Challenges
6. Conclusion
Interior of Flight Simulator Cockpit
CLOSED COMBAT GUNNERY TRAINER
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COMING TOGETHER
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HIGH TECH POLYMER “SAMPLES”
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100,000
Employees
$53.0 B2018 Annual Revenue
4Business
Areas
100$BBacklog
590+Sites
50 States
70 Countries
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AeronauticsMissiles and Fire Control
• Advanced aircraft design and production
• Modification and support
• Stealth technology
• Systems integration
• Guided and unguided Missiles
• Manned and unmanned combat systems
• Launch platforms
• Electro Optical Navigation and Targeting Systems
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Rotary and Mission Systems
Space Systems
• Helicopters design and production
• Naval Littoral Combat Ships
• Integrated Warfare System and sensors
• C6ISR and Undersea Systems
• Cyber Security Solutions
• Simulation and Training
• Designs and build spacecraft for deep space exploration
• Telecommunication, Climate, GPS Satellites
• Space Vehicles - Juno, Orion
WHAT WE DO
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THE 5 P’S
TM
PROPOSAL
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• Tradeshow Models
• Idea/Concept Communication
• Architectural and Site Plans
PROTOTYPES
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• Proof Of Concept
• Functional prototypes
• Design Validation
• Communication at design reviews
DESIGN BY DAYPRINT BY NIGHT
PROCUREMENT
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• Supply Chain Risk Management
• Transportation and Inventory costs
• Localized/Distributed Manufacturing
PRODUCTION SUPPORT
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• Assembly Fixtures
• Manufacturing tooling
• Production Templates
• Inspection and QA Jigs
• Machine Safeguarding
• Shop Floor Organization
FACTORY FLOOR INNOVATIONS
PRODUCTION
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• End Use Parts
• Obsolescence Management
• Spares, Warranty, and Repairs
• Parts on Demand - Sustainment
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THE 5 P’S
TM
VALUE PROPOSITION OF AM IN SIMULATION INDUSTRY
MILITARY TRAINERS ARE IDEAL PROVING GROUNDS
FOR ADDITIVE TECHNOLOGYLOCKHEED MARTIN PROPRIETARY INFORMATIION
Complexity(AM-Value)
Volume(Tooling $)
Criticality (Risk)
Aerospace/Defense
Military Simulators & Trainers
FootwearCell Phone covers
ADDITIVE APPLICATIONS IN MILITARY GROUND SIMULATORS
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ADDITIVE IN LIEU OF TACTICAL ASSETS
Gunnery Controls
Electronic Housings
Surrogate Parts
Equipment ClusterConsolidation
Instrument Panels
Closed Combat Tactical Trainer
PART COUNT REDUCTION THROUGH ADDITIVE
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PART CONSOLIDATION
CURRENT AM TECHNOLOGY CHALLENGES
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Model Make Measure
• Advanced sensors for in-situ monitoring and feedback
• Big data analytics for AM
• Machine learning
• Real-time quality/dimensional analysis during build
• Material characterization
• Standards for feedstock
• New functional material development
• Material lifecycle management –recycle/safety
• Integrated computation materials engineering – ICME tools
• Digital thread
• Generative design
• Physics-based predictive modeling and simulation
• Certification and qualification
• Repeatable, reliable, durable
• Lifetime performance studies
• Eliminate/reduce voids and interlayer adhesion
• Void detection methodology
4Material
CONCLUSION
1. Perception is Reality
2. Bring Others Along - The 5Ps
3. Get Big Wins Early
4. Challenges…The 4Ms
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